How to achieve full coverage of the industry for automatic center winders through modular design?

There are significant "material-process" adaptation problems in the field of sheet/thin plate processing:
Elastic deformation control
PET film is prone to elastic retraction during the winding process, resulting in core collapse or surface wrinkles. Traditional equipment is difficult to adapt to the dynamic changes of material thickness (0.1mm-1.2mm) and line speed (1-100m/min) through fixed tension control, and the winding diameter error is often up to ±2%.

Static adsorption problem
PS sheets are prone to generate static electricity up to 10kV during friction, causing materials to adsorb each other or dust, directly affecting the accuracy of downstream printing, lamination and other processes. Traditional anti-static measures (such as ion blowers) have defects such as limited coverage and high energy consumption.

Temperature sensitivity
Engineering plastics such as PC and ABS are prone to softening and deformation at high temperatures and brittle cracking at low temperatures. Traditional cooling systems are difficult to achieve dynamic temperature control during the winding process, resulting in residual stress in the material and affecting the quality of injection molding.

The modular design of the automatic center winder is based on three technical principles:
Functional decoupling
The winding process is decomposed into three independent module layers: "basic motion control", "material adaptation" and "environmental control", and the layers communicate through standardized interfaces. For example, the pressure compensation module only needs to interact with the servo motor control layer without changing the mechanical structure.

Dynamic combination
Through the module hot-swap technology, users can replace or add functional modules while the equipment is running. For example, when processing PET film, the pressure compensation module can be quickly inserted, and the system automatically recognizes and adjusts the control algorithm.

Software-defined hardware
Each module has a built-in microprocessor and functional expansion is achieved through firmware upgrades. For example, the anti-static module can be upgraded to the "static field visualization" function to display the charge distribution on the surface of the material in real time.
Technical implementation:
Mechanical interface standardization: Adopt ISO 10473 standard pneumatic shaft interface, compatible with 3-inch/6-inch shaft diameter, module replacement time <5 minutes.
Electrical interface unification: All modules communicate with the main control system through the CAN bus and support plug-and-play.
The software architecture is layered: the three-level architecture of the basic layer (motion control), the adaptation layer (material property processing), and the application layer (process parameter preset) ensures that the modules do not interfere with each other.

Industry adaptation strategy: Accurately match material properties
1. Pressure compensation module (to deal with elastic deformation of PET film)
Principle: The laser displacement sensor monitors the change of winding diameter in real time, and the servo motor dynamically adjusts the tension compensation value.

Function:
Adaptive elastic coefficient: Built-in elastic database of materials such as PET and PP, automatically matching compensation parameters.
Anti-wrinkle control: Increase tension in the early stage of winding (small winding diameter), and reduce tension in the later stage (large winding diameter) to avoid material accumulation.
Edge compensation: For ultra-thin materials (such as 0.1mm PET), the edge tension compensation algorithm is used to increase the winding flatness by 40%.

2. Anti-static module (to deal with electrostatic adsorption of PS sheets)
Principle: Combine electrostatic field simulation with ion neutralization technology to form a controllable electrostatic field during the winding process.

Function:
Electrostatic field visualization: Real-time display of material surface charge distribution through sensor array.
Ion concentration adjustment: Automatically adjust the ion wind intensity according to the material thickness to eliminate static electricity without secondary pollution.
Anti-static life extension: The module has a built-in self-cleaning function, and its service life is 3 times longer than that of traditional ion blowers.

3. Other industry adaptation modules
Temperature control module: For materials such as PC and ABS, it provides ±1°C winding environment temperature control.
Dust protection module: Prevent dust adsorption through a negative pressure system, suitable for optical grade PS sheet processing.
Intelligent deviation correction module: Using machine vision technology, it automatically corrects material deviation with an accuracy of ±0.1mm.